Modified Halbach Array Generator

ABSTRACT

A generator is described that includes a modified elongated Halbach array of magnets and a second array of magnets that interact to provide a flux field, which in turn interacts with a coil to generate an electrical current. The modified Halbach array includes two sets of magnets that are interspersed. In a first set of magnets the individual magnetic units are arranged in groupings of at least two magnets that are adjacent to one another and have the same magnetic orientation. In the second set of magnets utilizes either individual magnetic units or small groupings of individual magnetic units (relative to the first set of magnets) that are arranged in a different magnetic orientation than the first set, but identical to one another. A controller modifies electrical communication between different coils and/or controls inverters associated with the coils in order to control and stabilize electrical output from the generator.

This application is a continuation of U.S. patent application Ser. No.14/290,741, filed May 29, 2014, which claims priority to U.S.Provisional Application Ser. No. 61/828,410, filed May 29, 2013. Thatapplication, and all other extrinsic materials identified herein areincorporated by reference to the same extent as if each individualpublication or patent application were specifically and individuallyindicated to be incorporated by reference. Where a definition or use ofa term in an incorporated reference is inconsistent or contrary to thedefinition of that term provided herein, the definition of that termprovided herein applies and the definition of that term in the referencedoes not apply.

FIELD OF THE INVENTION

The field of the invention is generators and, more particularly,magnetic generators.

BACKGROUND

The background description includes information that may be useful inunderstanding the present invention. It is not an admission that any ofthe information provided herein is prior art or relevant to thepresently claimed invention, or that any publication specifically orimplicitly referenced is prior art.

Halbach array systems and other permanent magnet configurations havebeen used for many applications, such as coupling systems (e.g., U.S.Pat. No. 6,841,910 to Gery and U.S. Pat. Pub. 2013/0113317 to Englert)and electromagnetic machines that convert mechanical energy toelectrical energy. Typical electromagnetic machines have a rotor and astator. The rotor contains magnets and the stator contains windings tocarry the electric current through the coils. While the basicconfiguration of electromagnetic machines is known, such machines appearto be fairly limited in efficiency.

One example of an electromagnetic machine is U.S. Pat. No. 7,105,979 toGabrys, which discloses a heteropolar hybrid machine for convertingbetween electrical and mechanical energy. The machine has a rotor thatcomprises ferromagnetic and permanent magnet poles around itscircumference and a stator having a field coil and an armature locatedin an armature air gap of the rotor. The field coil generates a fieldcoil flux and the permanent magnet poles generate a permanent magneticflux that both flow through the armature air gap through theferromagnetic rotor structure to induce AC voltage in multiphasewindings of the armature. However, a larger air gap is required betweenthe rotor and stator to place the windings, which may increase thedemand of magnetomotive force.

Other examples of known electromagnetic machines can be found in U.S.Pat. No. 8,193,657 to Paluszek and U.S. Pat. No. 8,397,369 to Smith.Unfortunately, known efforts apparently failed to appreciate optimizedmagnetic flux configurations.

Thus, there is still a need for improved magnetic generators.

SUMMARY OF THE INVENTION

The inventive subject matter provides apparatus, systems and methods inwhich a generator has a first array of magnets and a second array ofmagnets. The first array of magnets is disposed in a first elongatedHalbach configuration, and the second array of magnets is disposed in asecond elongated Halbach configuration. The first elongated Halbachconfiguration includes sets of two or more first magnets arrangedadjacent to one another and with identical magnetic orientations, andsets of a smaller number of second magnets arranged in a second,different magnetic orientation. The magnetic orientation of the firstand second arrays of magnets influences the flux field of each array ofmagnets, such that a figure eight flux field is created between thefirst and second arrays. The generator further includes at last one coilthat is disposed between the first and second arrays, such that relativemovement of the first and second arrays with respect to the first coilgenerates an electrical current. Some embodiments include an additionalpair of magnet arrays that are similarly composed and arranged. Someembodiments include multiple coils and a controller that is configuredto manipulate electrical communication between the coils to controlamperage and voltage output. In other embodiments the controller isconfigured to control two or more inverters in order to more evenlydistribute load.

Various objects, features, aspects and advantages of the inventivesubject matter will become more apparent from the following detaileddescription of preferred embodiments, along with the accompanyingdrawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a perspective view of a generator of the inventive subjectmatter.

FIGS. 2A and 2B are perspective views the coil and ring arrangement ofthe generator of FIG. 1.

FIG. 3 is a cross-sectional view of a portion of the generator of FIG.1.

FIG. 4A is top view of one of the coils of the generator of FIG. 1.

FIG. 4B is a cross-sectional view of the coil of FIG. 4A.

FIG. 5 is a perspective view of first and second arrays of magnetsproducing a figure eight flux field in the generator of FIG. 1.

FIG. 6 is a top view of a current flow path produced by the flux fieldof FIG. 5.

FIG. 7 is a top view of the generator of FIG. 1, depicting first,second, third and fourth coils.

FIGS. 8A-8C are top views of a coil of FIG. 1, depicting series andparallel coil configurations.

FIG. 9 is a perspective view of the generator of FIG. 1, depicting amultiple ring assembly.

FIGS. 10A-10B are top views of a multiple coils of the generator of FIG.1, depicting single phase and multiple phase configurations.

DETAILED DESCRIPTION

The following description includes information that may be useful inunderstanding the present invention. It is not an admission that any ofthe information provided herein is prior art or relevant to thepresently claimed invention, or that any publication specifically orimplicitly referenced is prior art.

FIG. 1 shows an example of a generator 100 having a first ring 101, asecond ring 103, and a coil (not shown) within a coil shoe 107. Firstring 101 has a first array of magnets, and second ring 103 has a secondarray of magnets. Each of the first and second arrays of magnets isdisposed within the rings such that the arrays of magnets are fullyencapsulated by the material of the ring (e.g., composite fullyencapsulating array of magnets). However, in other contemplatedembodiments, at least one of the first and second arrays of magnets canbe partially encapsulated. Regardless of the mounting of the arrays, itis generally preferred that the first and second arrays of magnets aredisposed along the inner circumference of first ring 101 and second ring103.

Coil shoe 107 is mounted on a coil base 109 in a position between thefirst ring 101 and the second ring 103, and in a position that alignsthe coil (inside coil shoe 107) between the first and second arrays ofmagnets. The magnetic orientation of generator 100 allows a flux of thefirst array of magnets and a flux of the second array of magnets tointeract and manipulate the net flux field to form a figure eight fluxfield between the first and the second array of magnets (see FIG. 5).Coil shoe 107 is mounted on coil base 109, and typically remainsstationary (i.e., does not rotate) while first ring 101 and second ring103 rotate. In that manner, relative movement of the first and secondarrays of magnets with respect to the coil generates an electriccurrent.

First ring 101 and second ring 103 can be made of any suitablematerials. For example, at least one of first ring 101 and second ring103 can be a metal or metal alloy, or a composite (e.g., fiber resininfused composite). Additionally, first ring 101 and second ring 103 canhave any suitable sizes. In one embodiment, at least one of first ring101 and second ring 103 has a diameter of at least 0.125 meters. WhileFIG. 1 shows first ring 101 and second ring 103 having a similar size,it is contemplated that first and second rings could differ in size solong as the first and second arrays of magnets of each ring caninteract.

First ring 101 preferably has ring cooling holes 105 along its outercircumference to provide passive cooling by allowing airflow throughgenerator 100. As shown in FIG. 1, first ring 101 can have a pluralityof ring cooling holes 105 to provide cooling. The plurality of ringcooling holes 105 can provide a viewing area for inspecting theplacement of coil shoe 107. Additionally, second ring 103 can also havering cooling holes 105 to provide further cooling throughout generator100.

Coil shoe 107 can be made of a composite (e.g., a fiber resin infusedcomposite) and can also have a coil cooling hole 111. As mentionedabove, coil shoe 107 is located between first ring 101 and second ring103.

FIGS. 2A and 2B provide an example of a coil shoe 207 and first 201 andsecond ring 203 arrangements. Coil shoe 207 is positioned on coil base209 between first ring 201 having ring cooling hole 205 and second ring203. As shown, a portion of coil shoe 207 can be placed in the gapbetween first ring 201 and second ring 203. Most preferably, the portionof coil shoe 207 placed in the space between first ring 201 and secondring 203 comprises the coil. Moreover, in other contemplatedembodiments, the portion of coil shoe 207 placed in the space betweenfirst ring 201 and second ring 203 could also comprise coil cooling hole211.

FIG. 3 shows a cross sectional view of generator 300 having first ring301 and second ring 303. First ring 301 and second ring 303 are spacedapart by a ring gap 317. In contemplated embodiments, ring gap 317 canbe increased or decreased by use of a mechanism (e.g., hydraulic pump,electrical motor, magnets). Increasing or decreasing air gap 317 canprovide several benefits. For example, one benefit is that increasingring gap 317 allows generator 300 to accommodate larger coils. Anotherbenefit is that decreasing ring gap 317 increases flux density toproduce more power.

First ring 301 can have a first magnet 313 of the first array ofmagnets. First magnet 313 can comprise a rare earth material. Secondring 303 can have a second magnet 315 of the second array of magnets.Second magnet 315 can also comprise a rare earth material. As shown inFIG. 3, first magnet 313 and second magnet 315 can be aligned along thesame vertical axis, such that first magnet 313 is located directly abovesecond magnet 315. However, it is contemplated that first magnet 313 andsecond magnet 315 can be aligned in different orientations. For example,first magnet 313 can be positioned at an angle with respect to secondmagnet 315.

As shown in FIG. 3, first magnet 313 of the first array of magnets isseparated from second magnet 315 from the second array of magnets isseparated by ring gap 317. Ring gap 317 comprises a portion of coil shoe307 (the portion encapsulating the coil) and an air gap. In contemplatedembodiments, the first and second array of magnets are separated by ringgap 317 comprising a coil and an air gap of at least 3% of a thicknessof the coil, but preferably not more than 30%.

First magnet 313 and second magnet 315 can be encapsulated within firstring 301 and second ring 303, respectively. Moreover, first magnet 313and second magnet 315 can be disposed along the inner circumference offirst ring 301 and second ring 303, such that coil (encapsulated withincoil shoe 307) remains stationary along the inner circumference ofgenerator 300 (see orientation of coil and rings in FIG. 1) while firstring 301 and second ring 303 rotate.

FIGS. 4A and 4B show an example of a coil shoe 407 having a coil coolinghole 411. FIG. 4B shows a cross-sectional view of coil shoe 407 in FIG.4A. Coil shoe 407 has a coil 417 and a pair of output taps 419. Coil 417is preferably located near coil cooling hole 411. In contemplatedembodiments, coil 417 is a copper coil.

Output taps 419 can be used to harness the power produced by thegenerator. In other contemplated embodiments, at least one of outputtaps 419 can be used to connect coil 417 to more coils in singular ormultiple groups. Moreover, coil 417 can connect to other coils in seriesor parallel configuration to control amperage and voltage output. In atypical generator system having a number of installed magnets and anumber of installed coils, the ratio between the number of installedmagnets and the number of installed coils is at least 5:1 or morepreferably at least 10:1.

FIG. 5 shows a side perspective view of an example of a first array ofmagnets 521 and a second array of magnets 523 producing a figure eightflux field 525. As shown, first array of magnets 521 and second array ofmagnets 523 are disposed in a first elongated Halbach configuration.Unlike traditional Halbach array configurations (having a rotatingpattern of left, up, right, down), first array of magnets 521 and secondarray of magnets 523 have an elongated pattern (right, right, down,left, left, up). The magnetic orientation of first array of magnets 521creates a flux field that is interacting and complementing the fluxfield of second array of magnets 523. Thus, a net flux field ismanipulated to form a figure eight flux field 525 between the first 521and second arrays 523.

As described above, a coil is placed between the first 521 and secondarrays 523, such that the relative movement of the first 521 and secondarrays 523 with respect to the coil generates an electric current. WhileFIG. 5 shows a first 521 and second array 523 having magnets with nogaps, it is contemplated that an array can be configured to have atleast on gap between the plurality of magnets.

FIG. 6 shows an example of a current flow path 627 produced by the fluxfield in FIG. 5. Current flow path 627 is perpendicular to the fluxfield of FIG. 5. Having knowledge of the current flow path 627 producedby the flux field in FIG. 5, it should be appreciated that a coil can bearranged between a first and second array of magnets so that the currentgenerated is flowing in the same direction of the coil at all times.

FIG. 7 shows generator 700 comprising a first coil shoe 707, a secondcoil shoe 729, a third coil shoe 731, and a fourth coil shoe 733 mountedon coil base 709, each of which is partially disposed between the firstand second arrays of magnets disposed along the inner circumference ofthe first ring 701 and a second ring (not shown). The first 707, second729, third 731 and fourth coil shoes 733 have a first coil, second coil,third coil and fourth coil, respectively, that is at least partiallyembedded within the coil shoe. In preferred embodiments, the first,second, third and fourth coils are disposed between the first and secondarrays of magnets.

Generator 700 can further comprise a controller that configures thefirst, second, third and fourth coils in different series and parallelconfigurations to control amperage and voltage output as shown in FIGS.8A-8C. FIG. 8A shows coil shoe 807 having coil 817 and output taps 819for coupling other devices using at least one of a positive and negativeside output taps 819. FIG. 8B shows a coil 817 and second coil 849connected in a series configuration using output taps 819 and 841. Thenegative side of output tap 819 in coil shoe 807 connects to thepositive side of output tap 841 of coil shoe 829 to create a seriesconnection. In an exemplary embodiment, coil 817 has 1× volt and secondcoil 849 has 1× volt, such that a series configuration can produce 2×volts and 2 amps. FIG. 8C shows coil 817 and second coil 849 connectedin a parallel configuration using output taps 819 and 841. The positivesides of output taps 819 in coil shoe 807 and output taps 841 in coilshoe 829 join to create a parallel configuration.

Additionally, the controller can be configured to pre-load at least oneof the first, second, third and fourth coils or any multiples thereof,which is allowed by the geometry and space available provided by thecircumference of the rings. The controller can be configured to programfirst and second inverters to engage output from the coils in evenlydistributed loading as not to impede the generating device.

In another aspect, multiple rings can be stacked vertically to increasegenerator power output and size. For example, FIG. 9 shows generator 900having a first ring 901 and a second ring 903 having a first array ofmagnets and a second array of magnets, respectively. First coil in firstcoil shoe 907 is disposed between first and second array of magnets toproduce power as described in the embodiments above.

Generator 900 further includes third ring 935 having a third array ofmagnets disposed in a third elongated Halbach configuration and a fourthring 937 having a fourth array of magnets disposed in a fourthconfiguration (e.g., fourth elongated Halbach configuration). The thirdand fourth arrays can be configured to manipulate a second net fluxfield to form a second figure eight flux field between the third andfourth arrays. Second coil shoe 939 is disposed between the third andfourth arrays, such that relative movement of at least one of the thirdand fourth arrays with respect to the second coil generates additionalelectric current.

It should be appreciated that the generators disclosed herein can beconfigured as either a single phase magnetic motor or a multi-phasemagnetic motor by adjusting the coil placement to allow for eitherapplication as shown in FIGS. 10A-B. FIG. 10A shows single phase coilshoe arrangement 1043 having a plurality of coil shoes 1045 partiallydisposed below array of magnets 1047. FIG. 10B shows multiple phase coilshoe arrangement 1049 having a plurality of coil shoes 1045 producingthree phases. Contemplated embodiments require that the coils are placed120 degrees out of phase to produce a three phase configuration. Forexample, a three coil shoe arrangement comprises a distance betweenfirst and second coils at 1X and a distance between the second and thirdcoils at 2X.

The generators disclosed herein can be used in various power generationsystems. For example, the generators can be used in turbine systems(e.g., vertical axis turbines) and other systems that can generatemechanical energy to rotate the array of magnets.

In some embodiments, the numbers expressing quantities of ingredients,properties such as concentration, reaction conditions, and so forth,used to describe and claim certain embodiments of the invention are tobe understood as being modified in some instances by the term “about.”Accordingly, in some embodiments, the numerical parameters set forth inthe written description and attached claims are approximations that canvary depending upon the desired properties sought to be obtained by aparticular embodiment. In some embodiments, the numerical parametersshould be construed in light of the number of reported significantdigits and by applying ordinary rounding techniques. Notwithstandingthat the numerical ranges and parameters setting forth the broad scopeof some embodiments of the invention are approximations, the numericalvalues set forth in the specific examples are reported as precisely aspracticable. The numerical values presented in some embodiments of theinvention may contain certain errors necessarily resulting from thestandard deviation found in their respective testing measurements.

Unless the context dictates the contrary, all ranges set forth hereinshould be interpreted as being inclusive of their endpoints andopen-ended ranges should be interpreted to include only commerciallypractical values. Similarly, all lists of values should be considered asinclusive of intermediate values unless the context indicates thecontrary.

As used in the description herein and throughout the claims that follow,the meaning of “a,” “an,” and “the” includes plural reference unless thecontext clearly dictates otherwise. Also, as used in the descriptionherein, the meaning of “in” includes “in” and “on” unless the contextclearly dictates otherwise.

The recitation of ranges of values herein is merely intended to serve asa shorthand method of referring individually to each separate valuefalling within the range. Unless otherwise indicated herein, eachindividual value is incorporated into the specification as if it wereindividually recited herein. All methods described herein can beperformed in any suitable order unless otherwise indicated herein orotherwise clearly contradicted by context. The use of any and allexamples, or exemplary language (e.g. “such as”) provided with respectto certain embodiments herein is intended merely to better illuminatethe invention and does not pose a limitation on the scope of theinvention otherwise claimed. No language in the specification should beconstrued as indicating any non-claimed element essential to thepractice of the invention.

Groupings of alternative elements or embodiments of the inventiondisclosed herein are not to be construed as limitations. Each groupmember can be referred to and claimed individually or in any combinationwith other members of the group or other elements found herein. One ormore members of a group can be included in, or deleted from, a group forreasons of convenience and/or patentability. When any such inclusion ordeletion occurs, the specification is herein deemed to contain the groupas modified thus fulfilling the written description of all Markushgroups used in the appended claims.

One should appreciate that the disclosed techniques provide manyadvantageous technical effects including efficient power generationusing a magnified flux field effect having figure eight geometry.

The following discussion provides many example embodiments of theinventive subject matter. Although each embodiment represents a singlecombination of inventive elements, the inventive subject matter isconsidered to include all possible combinations of the disclosedelements. Thus if one embodiment comprises elements A, B, and C, and asecond embodiment comprises elements B and D, then the inventive subjectmatter is also considered to include other remaining combinations of A,B, C, or D, even if not explicitly disclosed.

As used herein, and unless the context dictates otherwise, the term“coupled to” is intended to include both direct coupling (in which twoelements that are coupled to each other contact each other) and indirectcoupling (in which at least one additional element is located betweenthe two elements). Therefore, the terms “coupled to” and “coupled with”are used synonymously.

It should be apparent to those skilled in the art that many moremodifications besides those already described are possible withoutdeparting from the inventive concepts herein. The inventive subjectmatter, therefore, is not to be restricted except in the spirit of theappended claims. Moreover, in interpreting both the specification andthe claims, all terms should be interpreted in the broadest possiblemanner consistent with the context. In particular, the terms “comprises”and “comprising” should be interpreted as referring to elements,components, or steps in a non-exclusive manner, indicating that thereferenced elements, components, or steps may be present, or utilized,or combined with other elements, components, or steps that are notexpressly referenced. Where the specification claims refers to at leastone of something selected from the group consisting of A, B, C . . . andN, the text should be interpreted as requiring only one element from thegroup, not A plus N, or B plus N, etc.

What is claimed is:
 1. A generator, comprising: a first array of magnetsdisposed in a first magnet configuration comprising a first elongatedHalbach configuration; a second array of magnets disposed in a secondmagnet configuration, wherein the second array of magnets is separatedfrom the first array of magnets by an adjustable gap comprising a ringgap; an actuator coupled to at least one of the first array and thesecond array, wherein the actuator is configured to adjust the ring gap;and a coil disposed between the first array of magnets and the secondarray of magnets such that relative movement of the first array ofmagnets and the second array of magnets with respect to the coilgenerates an electric current.
 2. The generator of claim 1, furthercomprising a first ring comprising the first array of magnets and asecond ring comprising the second array of magnets.
 3. The generator ofclaim 2, wherein at least one of the first ring and the second ringcomprises at least one cooling hole positioned to provide cooling on airflow through the generator.
 4. The generator of claim 1, wherein thecoil is disposed in a coil shoe coupled to a coil base, and wherein thecoil base is stationary and the first ring and the second ring areconfigured to rotate.
 5. The generator of claim 1, wherein the secondmagnet configuration comprises a second elongated Halbach configuration.6. The generator of claim 1, wherein the first coil is disposed on acoil base that is stationary.
 7. The generator of claim 1, wherein thering gap comprises the first coil and an air gap of at least 3% of athickness of the first coil.
 8. The generator of claim 1, wherein thefirst coil is disposed within a fiber resin infused composite.
 9. Thegenerator of claim 1, wherein the first array of magnets comprises arare earth material.
 10. The generator of claim 1, having a number ofinstalled magnets and a number of installed coils, and wherein a ratiobetween the number of installed magnets and the number of installedcoils is at least 10:1.
 11. The generator of claim 1, further comprisingsecond, third and fourth coils, each of which is disposed between thefirst and second arrays.
 12. The generator of claim 11, furthercomprising a controller that configures the first, second, third andfourth coils in different series and parallel configurations to controlamperage and voltage output.
 13. The generator of claim 11, furthercomprising a controller that is configured to pre-load at least one ofthe first, second, third and fourth coils.
 14. The generator of claim 1,further comprising a controller that configures first and secondinverters to engage output from the coils in evenly distributed loadingas not to impede the generator.
 15. The generator of claim 1, whereinthe first array of magnets comprises a first magnet arranged along afirst axis and the second array of magnets comprises a second magnetarranged along a second axis, wherein the first axis and the second axisare angled relative to one another.
 16. The generator of claim 1,wherein the first array of magnets is configured as a first ring havinga first radius and the second array of magnets is configured as a secondring having a second radius, wherein the first radius and the secondradius are different.